Rail assessment device

ABSTRACT

A travelling device may travel along a heavy machinery rail. The traveling device may collect positioning data to assess rail condition and/or installation. The positioning data may be collected using self-contained positioning sensors. Positional deviations indicating an elevated portion, a skewed portion, and/or a twisted portion of the heavy machinery rail may indicate issues with rail condition and/or installation.

RELATED APPLICATIONS

This application is a continuation of U.S. Non-Provisional applicationSer. No. 16/836,328, filed Mar. 31, 2020, pending, which claims thebenefit of U.S. Provisional Application No. 62/827,518, filed Apr. 1,2019, expired, all of which are incorporated by reference in theirentireties.

TECHNICAL FIELD

This disclosure relates to a device for rail positioning and conditionassessment.

BACKGROUND

Heavy machinery, such as cranes, on rail installations are used invarious industries include manufacturing, energy, and shipping. Cranesare capable of lifting loads of many tons while themselves weighing manytons. Thus, crane rails may experience large loads and large physicalstrain. Proper installation of rails is critical to on-site safety andavoidance of undue maintenance expenses. For example, in some cases,crane wheels alone may cost many thousands of dollars to replace.Accordingly, demand for systems to support proper installation andassessment of installed crane rail condition will remain high.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows cut-away and side views of an example travelling devicewith a wheelbase.

FIG. 2 shows a perspective view of the example travelling device.

FIG. 3 shows a top view of the of the example travelling device.

FIG. 4 shows cut-away and perspective views of a second exampletraveling device with a heavy-machinery fastener.

FIG. 5 shows example mobile hardware.

FIG. 6 shows an example method for assessing rail condition.

FIG. 7 shows an example method for assessing loaded rail condition.

DETAILED DESCRIPTION

In some cases, rail installation and condition may be assessed throughmeasurement of rail position and/or optical/visual inspection of therail. For example, a traveling device may capture position data as ittravels the span of a heavy machinery rail. Deviations in railstraightness, elevation, or twisting-type strains may cause thetraveling device to detect deviations using position sensors. Thetravelling device may be used to determine whether a rail meetsinstallation and/or safety guidelines.

In some cases, the travelling device may use self-contained positioningsensors. Self-contained positioning sensors may include positioningsensors that generate position data using resources contained within thesensor itself, such a gyroscopes, accelerometers, and/or magnetometers.Such self-contained positioning sensor may not necessarily be dependenton externally generated signals (such as laser and/or satellite signals)to generate position data. In some cases, non-self-contained positioningsensor may be used with the travelling device.

In the context of assessing rails for heavy industrial machinery, theuse of self-contained sensors goes against the conventional wisdom. Thetechnical problem of assessment of rail installation has previously beenframed as a problem of obtaining a survey of the rail contours.Accordingly, existing market solutions approach the task of railassessment using survey techniques and modified tools for suchtechniques. The use of self-contained sensors reframes the technicalproblem as a broader positioning data problem. Therefore, a selection oftools the conventional “survey” wisdom would overlook may be applied.For example, self-contained sensors used in navigation may be applied.The use of self-contained positioning sensors (potentially used inconnection with non-self-contained sensors) may allow for faster railassessment e.g., (tens of minutes, or assessment completed within alunch break) whereas even survey techniques modified for speed mayresult in a day of downtime. In some cases, non-self-contained sensorsrelying on satellite signals may have limited position resolution. Forexample, in some cases, a deviation of ¼ inch over a span of 20 feet maycause a rail to be out of compliance with an example guideline. However,in some cases, achievable positioning resolutions from publicallyavailable positioning satellite systems may be a few centimeters tomultiple feet. Further, signal reception may not necessarily be possiblein all locations where a rail assessment may be desired.

FIG. 1 shows cut-away and side views (198,199) of an example travellingdevice 100 with a wheelbase 150. The example traveling device 100 mayinclude a chassis 101 and a position sensor 102 (e.g., such as aself-contained position sensor). Optionally, the example travelingdevice may include a power source 104, a processor 106, memory 108,redundant self-contained position sensors 112, GPS sensors 114,radio/antenna (e.g., analog interfaces, data radio interfaces,Bluetooth, WiFi, cellular-data interfaces) 116, and/or remote controlinterface 118.

The wheelbase 150 may include one or more wheels 152. Optionally, thewheelbase 150 may include a motor, and a motor controller (notpictured). The one or more wheels may be spring loaded to couple to avariety of rail gauges. Further, the wheelbase 150 may be adjustable toaccommodate a variety of rail gauges. A distance sensor 154 may bedisposed on the wheelbase.

In some cases, such as where the wheelbase protrudes from the chassis101, the chassis 101 may include drive wheels 132, a motor 134, andmotor controller 136. Accordingly, an optional propulsion system may belocated within the chassis 101 and/or in the wheelbase 150.

In some cases, the wheelbase 150 may be disposed on the chassis 101 suchthat the wheelbase may extend down into the grooves of an embedded rail.However, the wheelbase may be implemented in other configurations, suchas one-sided configurations (e.g., configurations which grip the top andbottom of one side of the head of the rail), configurations embedded inthe chassis 101, and other configurations.

The wheelbase may optionally include a distance sensor 154 such as asonic distance sensor, an optical distance sensor, a radar distancesensor or other distance sensor. The distance sensors may measure aclearance from the rail (e.g., a rail center, edge or other referencepoint) to obstructions such as columns and other potential obstructions.The wheelbase may be positioned such that the wheels in the wheelbaserun along the head of rail. In some cases, the wheelbase may bepositioned such that the wheels in the wheelbase run along the web ofthe rail, or, in some cases, multiple sets of wheels may run along boththe head and web of the rail.

In some cases, the traveling device 100 may include a laser and/orprism. In some implementations, the laser/prism may be used to execute ameasurement of a total span of the rail prior to assessment. In someimplementations, the laser/prism may be used to coordinate tandemoperation between two traveling devices 100 each running along a singleone of a pair of rails. The laser/prism pair (e.g., a laser source onone device reflecting off a prism mounted on the other) mounted on thetravelling device may allow the traveling devices to gauge theirrelative distance as they travel along the pair of rails. Thus, relativedeviations between the individual ones of the pair of rails may bedetermined.

FIG. 2 shows a perspective view 200 of the example travelling device100.

FIG. 3 shows a top view 300 of the of the example travelling device 100.The traveling device 100 may include an external antenna 302, which maybe removable in some implementations. The travelling device may includea display 304, which may be a touchscreen display in someimplementations. The traveling device may include a camera 306, whichmay be removable in some implementations, and a power I/O switch 308.The travelling device 100 may be configure to assess a rail conditionwhen the rail is in an unloaded state.

An example travelling device may include the TrackRunner® productprovided by Whiting Services, Inc. However, various othertravelling-device implementations may include or exclude features and/orcomponents present in the TrackRunner® product.

FIG. 4 shows cut-away and perspective views (498,499) of a secondexample traveling device 400 with a heavy-machinery fastener 450. Theexample traveling device 400 may include a chassis 401 and a positionsensor 102 (e.g., such as a self-contained position sensor). Optionally,the example traveling device may include a power source 104, a processor106, memory 108, redundant self-contained position sensors 112, GPSsensors 114, radio/antenna (e.g., analog interfaces, wireless datainterfaces: Bluetooth, WiFi, cellular-data interfaces) 116, remotecontrol interface 118.

The heavy-machinery attachment fastener 450 may include a fasteningstructure, such as a magnet, snap (e.g., male-female coupler) a socket(e.g., a specific socket structure configured to couple to acounter-part structure on the heavy-machinery, bolts, suction cup, orcombination thereof, to couple to a heavy machinery exterior or chassis,such as a metallic chassis. In some cases, the heavy-machineryattachment fastener 450 may include a permanent fastener such as epoxy,solder, a weld, rivet, or other permanent fastener. In some cases, thesecond example travelling device 400 may be configured to captureposition while the rail in a loaded state. For example, the secondexample travelling device 400 may measure rail deflection while heavymachinery (such as a crane) performs a loading action (e.g., a craneperforming a lift, a transport cart being loaded with cargo, a forkliftextending a jaw, a front-loader moving a bucket, a digger moving ashovel, or other loading action), or while heavy machinery traverses oneor more rails without performing a loading action. In some cases, thesecond example travelling device 400 may measure rail deflection betweensupport columns as the heavy machinery travels along the rail. Invarious implementations, support columns may be used to suspend the railabove a ground or floor levels. Support columns may be orientedvertically and spaced apart by an inter-column spacing. In some cases, aperiodic deflection pattern (that reflects the inter-column spacing) maybe expected for a rail in good condition. In some cases, an anomalousamount of deflection (compared to other sections (e.g., sections definedby the inter-column spacing) of rail) may provide an indication of railwear, damage, deterioration, or other rail degradation.

In various implementations, a travelling device 100, 400 may use thememory 108 to store position data (e.g., rail deflection position (e.g.,elevation and/or from straight along the span) or rail rotation data(e.g., rail twist which may change the angle of rail head with respectto the floor (or rail mount)) as the data is captured by the positionsensors. The memory may also include code or other operational softwareinstructions that may be used to operate the travelling device 100, 400.

The wireless data interfaces and/or the remote control interfaces may beused to control the traveling device remotely. In some cases, the remotecontrol interface may also be used to send telemetry data to or from thedevice. The wireless data interface may also allow a remote user toaccess captured position data in real-time.

The power source of the travelling device 100, 400 may include abattery, a battery charger, and/or a wired power socket that may be usedto power device and/or charge the battery.

The camera, which may be included in various implementations, may beused to capture optical images of the rail. In some cases, an automatedsoftware algorithm (such as a human-trained machine learning algorithm)and/or a person may review the images to determine points along the railthat may correspond to damage or deterioration of the rail. In somecases, the camera may be disposed on the exterior of the travellingdevice 100, 400 or disposed within the chassis with a window from whichto view the rail.

The self-contained position sensor may capture position data. In somecases, a positional deviation of more than ¼ inch over a span of 20 feetmay constitute an out-of-tolerance deviation. In some cases, positionalresolutions that are finer than that which could detect anout-of-tolerance deviation are captured. For example, a positionalresolution of up to 1/64 inch (deviation) over a span of 100 feet orgreater resolution may be used. In some cases, one or more single-axis(any one axis) position sensors may be used. In some cases, one or moretwo-axis position (e.g. x/z roll/pitch) sensors may be used. In somecases, one or more three-axis sensors (x/y/z roll/pitch/yaw) may beused. For example, a MPU-9250 position sensor and/or a MPU-6050 positionsensor may be used. In some cases, up to three or more independentlycalibrated and independently operational three-axis sensors may be usedas redundancy sensors. Anomalous data from a single sensor may berejected in view of consistent data from other sensors.

In various implementations, the position sensor (or the processor'sresponse to the raw output of the position sensor) may be calibrated toplace the starting point of the travelling device 100, 400 (e.g., for anew data collection run) at an origin (e.g., a zero point for the one ormore axes of the sensor).

In various implementations, the processor 106 may be used to processand/or compile position data captured by the sensors. The processor maycompile the data into various forms (comma separated value data,columnar data, or other data forms). The processor may also be used toexecute software to access and/or control positions sensors, GPSsensors, data interfaces, and/or execute software commands.

FIG. 5 shows example mobile hardware 500, which may be used as anexample sensing/computing backbone of the traveling device 100, 400. Inthis example, the mobile hardware 500 may support one or more SubscriberIdentity Modules (SIMs), such as the SIM1 502. Electrical and physicalinterface 506 connects SIM1 502 to the rest of the user equipmenthardware, for example, through the system bus 510.

The mobile hardware 500 includes communication interfaces 512, systemlogic 514, and a user interface 518. The system logic 514 may includeany combination of hardware, software, firmware, or other logic. Thesystem logic 514 may be implemented, for example, with one or moresystems on a chip (SoC), application specific integrated circuits(ASIC), discrete analog and digital circuits, and/or other circuitry.The system logic 514 is part of the implementation of any desiredfunctionality in the mobile hardware 500. In that regard, the systemlogic 514 may include logic that facilitates, as examples, runningapplications; accepting user inputs; saving and retrieving applicationdata; establishing, maintaining, and terminating data connections for,as one example, Internet connectivity; establishing, maintaining, andterminating wireless network connections, Bluetooth connections, orother connections; and/or displaying relevant information on the userinterface 518. The user interface 518 and the inputs 528 may include agraphical user interface, touch sensitive display, haptic feedback orother haptic output, voice or facial recognition inputs, buttons,switches, speakers and other user interface elements. Additionalexamples of the inputs 528 include microphones, video and still imagecameras, temperature sensors, vibration sensors, rotation andorientation sensors, headset and microphone input/output jacks,Universal Serial Bus (USB) connectors, memory card slots, radiationsensors (e.g., IR sensors), and other types of inputs.

The system logic 514 may include one or more processors 516 and memories520. The memory 520 stores, for example, control instructions 522 thatthe processor 516 executes to carry out desired functionality for themobile hardware 500. The control parameters 524 provide and specifyconfiguration and operating options for the control instructions 522.The memory 520 may also store any BT, WiFi, 3G, 4G, 5G or other datathat the mobile hardware 500 will send, or has received, through thecommunication interfaces 512.

In various implementations, the system power may be supplied by a powersource 582, such as a battery.

The system circuitry may further include position sensors 594 which maysupply position data 596, which may be stored in the memory 520.

In the communication interfaces 512, Radio Frequency (RF) transmit (Tx)and receive (Rx) circuitry 530 handles transmission and reception ofsignals through one or more antennas 532. The communication interface512 may include one or more transceivers. The transceivers may bewireless transceivers that include modulation/demodulation circuitry,digital to analog converters (DACs), shaping tables, analog to digitalconverters (ADCs), filters, waveform shapers, filters, pre-amplifiers,power amplifiers and/or other logic for transmitting and receivingthrough one or more antennas, or (for some devices) through a physical(e.g., wireline) medium.

The transmitted and received signals may adhere to any of a diversearray of formats, protocols, modulations (e.g., QPSK, 16-QAM, 64-QAM, or256-QAM), frequency channels, bit rates, and encodings. As one specificexample, the communication interfaces 512 may include transceivers thatsupport transmission and reception under the 2G, 3G, BT, WiFi, UniversalMobile Telecommunications System (UMTS), High Speed Packet Access(HSPA)+, and 4G/Long Term Evolution (LTE), 5G standards. The techniquesdescribed below, however, are applicable to other wirelesscommunications technologies whether arising from the 3rd GenerationPartnership Project (3GPP), GSM Association, 3GPP2, IEEE, or otherpartnerships or standards bodies.

FIG. 6 shows an example method 600 for assessing rail condition,including loaded and/or unloaded rail condition. Optionally, measure afull span of the rail (602). Send a traveling device along the rail tocollect positioning data (604). Compile the positioning data (606).Store the positioning data on the memory (608).

FIG. 7 shows an example method 700 for assessing loaded rail condition.Collect positional data while heavy machinery performs an operation(e.g., a loading action, a traversal of a portion of the rail, or otheroperation) (704). Compile the positioning data (706). Store thepositioning data on the memory (708).

In various implementations, the travelling device may be temporarilyaffixed to the heavy machinery. Accordingly, the travelling device mayoptionally be affixed to the heavy machinery prior to performance of theoperation (702).

The architectures and techniques discussed above (in some cases withinthe context of illustrative examples) demonstrate general principles andstructures which may be implemented in various examples:

A1 In an example, a device includes: a chassis; a wheelbase coupled tothe chassis, the wheelbase configured to couple to a heavy machineryrail; a motor configured to provide propulsion to the wheelbase to causethe device to travel along the heavy machinery rail; and aself-contained position sensor disposed within the chassis, theself-contained position sensor configured to provide positional data forthe heavy machinery rail when the device travels along the heavymachinery rail.

A2 In an example, a device includes: a chassis; a wheelbase coupled tothe chassis, the wheelbase configured to couple to a heavy machineryrail; a motor to provide propulsion to the wheelbase along a directionof travel along the heavy machinery rail; and a position sensor disposedwithin the chassis, the position sensor configured to generaterotational position data for rotation about a rotational axis parallelto a direction of travel along the heavy machinery rail.

A3 The device of any of the preceding examples where: the wheelbase iscoupled to the bottom of the chassis; and the wheelbase is positioned tohold the chassis above the rail.

A4 The device of any of the preceding examples where a wheel of thewheelbase is positioned to run along a head of the rail, a web of therail, or both.

A5 The device of any of the preceding examples where a drive wheel iscoupled to the motor to propel the device along the heavy machineryrail; and optionally, the drive wheel is disposed within the chassis.

A6 The device of any of the preceding examples where a wheel of thewheelbase is spring-loaded.

B1 In an example, a device includes: a chassis; a heavy machineryattachment fastener to affix the chassis to heavy machinery; and aself-contained position sensor disposed within the chassis, theself-contained position sensor configured to provide positional data fora rail when the chassis is affixed to the heavy machinery and the heavymachinery operates while on the rail.

B2 In an example, a device includes: a chassis; a heavy machineryattachment fastener to affix the chassis to heavy machinery; and aposition sensor disposed within the chassis, the position sensorconfigured to generate rotational position data for rotation about arotational axis parallel to a direction of travel along a rail when thechassis is affixed to the heavy machinery and the heavy machineryoperates while on the rail.

B3 The device of example B1 or B2 where, the heavy machinery attachmentfastener includes a magnet configured to attach to a metallic heavymachinery chassis.

B4 The device of any of examples B1-B3, where the heavy machineryattachment fastener includes a specific socket configured to couple to acounterpart socket disposed on a heavy machinery chassis of the heavymachinery.

B5 The device of any of examples B1-B3, where the position sensor isconfigured to generate position data when the rail is in a loaded state.

C1 The device of any of the preceding examples where the device furtherincludes memory disposed within the chassis configured to store datafrom the position sensors.

C2 The device of any of the preceding examples where device furtherincludes: an antenna; and a radio configured to transmit output from theposition sensor.

C3 The device of example C2 or any of the preceding examples, where thedevice further includes: memory; and the radio includes a wireless datainterface.

C4 The device of example C3 or any of the preceding examples, where thewireless data interface includes a Wi-Fi compliant interface, aBluetooth compliant interface, a cellular data interface, or anycombination thereof.

C5 The device of example C3, C4, or any of the preceding examples, wherethe device in configured to accept command input from the wireless datainterface.

C6 The device of any of the preceding examples where the device includesa power source.

C7 The device of example C5 or any of the preceding examples where thepower source includes a battery, a wired power input, or both.

C8 The device of any of the preceding examples, where the device furtherincludes a camera disposed on the chassis.

C9 The device of example C8 or any of the preceding examples where thecamera is configured to capture images of the rail when the devicetravels along the rail.

C10 The device of any of the preceding examples where the positionsensor includes a three-axis position sensor.

C11 The device of any of the preceding examples where the positionsensor is configured to generate a relative position measurement.

C12 The device of any of the preceding examples where the positionsensor includes an accelerometer, a gyroscope, or both.

C13 The device of any of the preceding examples where the positionsensor is configured to measure pitch, roll, yaw, or any combinationthereof.

C14 The device of any of the preceding examples where the deviceincludes one or more redundancy position sensors configured toindependently generate data redundant with the positional data.

C15 The device of example C2, C8 or any of the preceding examples wherethe camera, the antenna or both are disposed on the exterior of thechassis.

C16 The device of example C15 or any of the preceding examples where thecamera, the antenna or both are removable from the device.

C17 The device of example C2, C8 or any of the preceding examples wherethe camera, the antenna or both are disposed within the chassis.

C18 The device of any of the preceding examples where the device furtherincludes a distance measuring sensor disposed within the chassis tomeasure clearance from the center of the rail.

C19 The device of example C18 or any of the preceding examples where thedistance measuring sensor includes a sonic sensor, a laser rangingsensor, an optical sensor, or any combination thereof.

C20 The device of any of the preceding examples where the device furtherincludes a microprocessor configured to process the position data,compile the position data of both.

C21 The device of any of the preceding examples where the device furtherincludes a display.

C22 The device of C21 or any of the preceding examples where the displayincludes a touchscreen interface.

D1 A method of manufacture: providing, disposing and/or coupling any ofor any combination of the components of any of the preceding examples.

E1 In an example, a method includes: optionally, measuring a span of arail; causing a travelling device to traverse the rail along the span;and capturing, via a self-contained position sensor of the travelingdevice, position data as the travelling device to traverses the railalong the span; and compiling the position data in reference to therail.

E2 The method of example E1, where measure the span of the rail includeusing a tape measure, a laser ranging device, or both.

E3 The method of either example E1 or E2 where the rail including one ofa pair of rails; and the method further includes repeating the othersteps of the method on the other of the pair of rails.

F1 In an example, a method includes: affixing a travelling device tomachinery disposed on a rail; causing the machinery to perform anoperation while on the rail; and while the machinery performs theoperation, collecting positional data via a self-contained positionsensor of the travelling device.

F2 The method of example F1, where the operation includes performance ofa loading action, a traversal of at least a portion of the rail, orboth.

F3 The method of either example F1 or F2, where: causing the machineryto perform an operation includes causing the machinery to traverse aportion of the rail; and collecting positional data includes capturing apattern in elevation data for the rail, the pattern formed as a resultof rail flex between support columns and loading the rail with themachinery.

F4 The method of any of examples F1-F3, further including identifying adegraded rail section by determining that elevation data for thedegraded rail section deviates from the pattern.

G1 The method of any of the preceding examples, further includingcalibrating the travelling device to place a starting point of thetravelling device at an axis origin.

G2 The method of any of the preceding examples, further includingcapturing a set of images of the rail while traversing the rail;optionally reviewing the set of images for a subset of images includingvisual indications of degradation; and optionally tagging the subset ofimages.

H1 The method of any of the preceding examples using the device of anyof the preceding examples.

Various implementations have been specifically described. However, manyother implementations are also possible.

What is claimed is:
 1. A device including: a chassis; a wheelbasecoupled to the chassis, the wheelbase configured to couple to a rail; amotor configured to cause the device to travel along the rail; and aself-contained position sensor fixed relative to the chassis, theself-contained position sensor configured to provide positional data forthe rail when the device travels along the rail.
 2. The device of claim1, where: the wheelbase is coupled to the bottom of the chassis; and thewheelbase is positioned to hold the chassis above the rail.
 3. Thedevice of claim 1, where a wheel of the wheelbase is positioned to runalong a head of the rail, a web of the rail, or both.
 4. The device ofclaim 1, where the device further includes memory disposed within thechassis configured to store data from the self-contained positionsensor.
 5. The device of claim 1, where device further includes: anantenna; and a radio configured to transmit output from theself-contained position sensor.
 6. The device of claim 1, where thedevice further includes a camera disposed on the chassis, the cameraconfigured to capture images of the rail when the device travels alongthe rail.
 7. The device of claim 1, where the self-contained positionsensor includes a three-axis position sensor.
 8. The device of claim 1,where the device includes one or more redundancy position sensorsconfigured to independently generate data redundant with the positionaldata.
 9. The device of claim 1, where the device further includes adistance measuring sensor disposed within the chassis to measureclearance from the center of the rail.
 10. The device of claim 9, wherethe distance measuring sensor includes a sonic sensor, a laser rangingsensor, an optical sensor, or any combination thereof.
 11. A deviceincluding: a chassis; a machinery attachment fastener to affix thechassis to machinery; and a self-contained position sensor fixedrelative to the chassis, the self-contained position sensor configuredto provide positional data for a rail when the chassis is affixed to themachinery and the machinery performs an operation while on the rail. 12.The device of claim 11, where the operation includes performance of aloading action, a traversal of at least a portion of the rail, or both.13. The device of claim 11, where the machinery attachment fastenerincludes a magnet, a socket, bolt, snap, suction cup, or any combinationthereof.
 14. The device of claim 1, where the device further includes acamera disposed on the chassis, the camera configured to capture imagesof the rail when the machinery travels along the rail.
 15. A methodincluding: affixing a travelling device to machinery disposed on a rail;causing the machinery to perform an operation while on the rail; andwhile the machinery performs the operation, collecting positional datavia a self-contained position sensor of the travelling device.
 16. Themethod of claim 15, where the operation includes performance of aloading action, a traversal of at least a portion of the rail, or both.17. The method of claim 15, where: causing the machinery to perform anoperation includes causing the machinery to traverse a portion of therail; and collecting positional data includes capturing a pattern inelevation data for the rail, the pattern formed as a result of rail flexbetween support columns and loading the rail with the machinery.
 18. Themethod of claim 17, further including identifying a degraded railsection by determining that elevation data for the degraded rail sectiondeviates from the pattern.
 19. The method of claim 15, further includingcalibrating the travelling device to place a starting point of thetravelling device at an axis origin.